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Most of our work since 2000 has been in developing grinding mill foundations to avoid vibration and unacceptable deflections. On a recent project for a plant in Peru, the client was told by the mill vendor that there was no need to do a systems dynamic analysis on the mill foundations because the mills on that project were gear driven rather than being driven by ring motors gearless drives. This shows a complete misunderstanding by mill vendors, or rather this particular mill vendor, about how mill foundations behave. We provide a large number of solutions for customers in more than 160 countries/regions around the world, and are committed to creating the most suitable solutions for customers. We welcome your inquiry 7/24 hours.
Get PriceThe most notable failures and difficulties in mill foundations have been caused by gear drives. Some examples we have worked on are.
Get QuoteMt LeyshonThe three foundations at Mt Leyshon all failed within a short time. The failures were catastrophic, i.e., the cracks in the piers completely failed and there was no way that the mills could be operated. In c. 1992, one of our staff was asked to determine why these foundations failed and to model a proposed fix. The failure was traced to the gear forces as these matched one of the natural frequencies of the foundation piers. Each mill was down for nearly a month while the repair was made and the concrete allowed to cure.
Get QuoteNorth ParkesThe next foundation we worked on was at North Parkes. There, the foundations on the original plant would transient manner. We were asked to design the foundation for the new plant from the point of view of vibration. A block between the mill bearing piers was required to avoid vibration that would have occurred due to the combination of raft dimension, mill frequencies and soil properties. There were no issues with vibration on these new foundations. This work then led on to the Cadia project and many others thanks to Geoff Cullen and Alan Boughey.
Get QuoteFimiston KCGMAnother interesting foundation we studied is the Fimiston SAG mill foundation. The gears on the mill on this foundation were very difficult to align and the alignment and vibration of the system was worse when the mill was rotated in one direction rather than the other. We found that the direction of rotation would result in a change in the vibration levels at the pinion piers of up to 7 times depending on the level of damping in the structure from 5 mms to 35 mms. This was the first analysis that explained why the direction of mill rotation affected on vibration levels.
Get QuoteFimiston mill foundations 8211Mill and soil not shown for clarity.
Get QuoteGearless Mill Drive FoundationsWe have never encountered a foundation vibration problem with operating gearless driven mills, although there may be examples of this about. The main problems with gearless driven mills is stiffness and strength there are several examples of cracked foundations at the supports for ring motors.
Get QuoteIn terms of actual vibration problems with ring motors, we know of the Cadia vibration issues only. There, we proved conclusively that the vibrations were not related to the design of the foundations.
Get Quote2 8211 Difference between Geared and Gearless Mill Foundation Design.
Get QuoteThere is a key difference in system analysis of geared and gearless mill foundations.
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Get QuoteSep 23 2014018332This means that SAG mill foundations behave very differently from ball mill foundations 4 Mill Designer Stiffness Criteria One of the mill designers performs a calculation to determine the target stiffness of the foundations given the mill and ring motor stiffnesses.
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Get QuoteSAG is an acronym for semiautogenous grinding SAG mills are autogenous mills that also use grinding balls like a ball mill A SAG mill is usually a primary or first stage grinder SAG mills use a ball charge of 8 to 21 The largest SAG mill is 42 128m in diameter.
Get QuoteCompany and services eandmhe work led on to foundation analysis work at north parkes and then cadia hill in 1996he analysis of the cadia sag and ball mill foundations were critical in the resolution of the stator vibration problem that arose during the commissioning of the 40 ft sag mill.
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